Yarn Winding: by M. Naveed Akhtar

Yarn winding
By
M. Naveed Akhtar
Yarn Winding- Past and Present
In the past winding of yarn was considered as
Simple
Unimportant
Non-productive process
Now it is considered important because it
Gives opportunity for faults removal
Gives opportunity to carry out yarn conditioning, yarn
waxing etc
Ensures increased processing efficiency of subsequent
processes
Types of Winding Packages
For single and plied yarns
Parallel-sided cheese
Cone
For sewing threads and synthetic filament yarns
Parallel-sided cheese
Spool
Parallel-Sided Cheese
A Spool
A Cone
Parallel sided Cheese
The winding and withdrawal of yarn are at constant
speed
The package can be unwound either by side
withdrawal and package rotation, or by over-end
withdrawal
Side Withdrawal
Package rotates while unwinding
The yarn unwinding speed will be limited
No change of twist during unwinding
Parallel sided Cheese
Over-end Withdrawal
Unwinding without package rotations
Chances of sloughing off fault of yarn due to
yarn/package friction
During unwinding the twist in yarn is changed (either
increased or decreased) by an amount equal to 1/πD
where D is package diameter
Hence all the packages should be placed same way up so
that unwinding is done in one direction of rotation only
Wind and traverse ratio
The Wind is the number of coils of yarn wound on
per single traverse from one end of the package to the
other
The Traverse Ratio is the number of coils of yarn
wound on per complete traverse cycle
The traverse ratio is twice the wind
A Cone
A cone is a more stable package compared to cheese
Sloughing off does not occur during handling and
unwinding due to minimum yarn/package friction
Cones are unwound over-end without package
rotation
They give low and relatively uniform unwinding
tension at high speeds
High speed winding can be done at about 1400 m/min
A twist is inserted (or removed) in the yarn for each
revolution of yarn withdrawn
A Cone
Longer length of yarn can be obtained on cones as
compared to cheeses
This increases the productivity of subsequent
processes
Cones can be made larger than cheeses
Usually cones can be made up-to 2 kg package mass,
but larger cones of up-to 5 kg can be made for carpet
yarns
Cone taper
The cone taper is the semi-
vertical angle, i.e. between the
cone axis and its sloping face
Types of Winding Machines
Precision winding
Drum winding or random winding
Precision Winding
The package is mounted on a spindle which is driven with the
help of an individual motor
Yarn passes through reciprocating yarn guides which are
driven by a cam shaft
There is no slippage in the device or uncontrolled
displacement of the yarn, therefore it is called precision
winding.
The ratio between the spindle speed and the traverse speed is
precise
Speed of conventional precision winder is limited by
traverse speed of yarn guide
To overcome it a grooved traverse roller is used to
reciprocate yarn
Now speeds of more than 1500 m/min have been
achieved
Sewing threads are usually precision wound on cones,
cheeses and spool
Drum Winding
Package is driven by surface contact with a motor driven
drum
Drum Winding
Speed of drum decreases as the package diameter
increases
The mean yarn speed is approximately constant
This results in uniform application of lubricants
As package diameter increases its angular velocity
decreases
The fault of patterning or ribboning occurs in drum
winding
Yarn would return to exactly the same starting point
The next set of coils are laid on top of previous ones
At yarn breakage the drum winding unit is stopped to
allow for yarn knotting or splicing
Yarn tensioning
Older machines used dead-weight loading over two
discs between which yarn passed
Most modern machines use disc tensioning devices
Yarn is drawn between two discs which have
adjustable spring loading to apply required tension
Winding tension causes weak places in yarn to break
This results in less stoppages in subsequent processes
Too high winding tension results in very hard package
but elastic properties of yarn will be affected
Length measuring system
The modern machines are equipped with good length
measuring systems to control the package weight
variation
The uniform package weight helps in reducing the
losses weight variation in dyeing and also reduce the
chances of excess dyeing and short falls
Balloon breakers
The modern machines are fitted with an adequate
balloon breaking device, which provides more
flexibility to use different size of feed packages and
also reduce the breakages rate
Yarn Knotting
In older machines
knotting was done
It was done either by
hand or by means of
mechanical knotters
Most common knots
used are dog knot,
fisherman’s (back-
to-back) knot and
weaver’s knot
Yarn Splicing
Yarn Splicing
It is the joining of yarn without knotting
Two broken ends of yarn are held and cut at splicing
point
These ends are inserted in an air vortex tube
It untwists the two yarns and extracts loose fibres to
taper them
These two ends are then drawn back until correct
length overlaps each other
A jet of turbulent air intertwines the fibres from two
ends to form a splice
Yarn Splicing
The twist of adjacent areas rushes to cover the joining
area
Hence the twist per inch at splice is less than original
yarn
This results in reduced yarn strength at splice
The yarn diameter at splice is nearly the same, hence it
is not visible in the fabric
Yarn Clearing
Yarn faults cause 10% stoppages in warping, 20% in
weaving
Mending is un-economical for cotton-spun materials
It is technically impractical in most knitted fabrics
Hence fault removal at the winding stage is desirable
Initially mechanical yarn clearers were used
Now electronic yarn clearers are in use
Photoelectric clearers
Capacitance clearers
Dual clearers (e.g. Uster Quantum Series)
Yarn Clearer by LOEPFE
Spinning Yarn Faults
- Neps
- Short Thicks
- Long Thicks
- Long Thins
- Count Channel
- Hairiness
- Contamination
Yarn Faults Removal
Foreign Matter Dark (FD) Channel
Dark and Light
Coloured
Contaminations

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